Laminates, and systems and methods for laminating

ABSTRACT

A frangible laminate includes first, second and third webs, and the second web is positioned between the first and third webs. The forming of the frangible laminate includes adhesively bonding a first plurality of sections of the second web to the first web, applying release material in order to inhibit at least some of any bonding between the first plurality of sections of the second web and the third web, and adhesively bonding a second plurality of sections of the second web to the third web. The frangible laminate is separated into a first laminate and a second laminate, so that the first laminate includes the first web and the first plurality of sections of the second web, and the second laminate includes the third web and the second plurality of sections of the second web.

CROSS-REFERENCED TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/960,771, filed Sep. 26, 2013, the entire disclosure of which isincorporated herein by reference.

FIELD OF THE DISCLOSURE

This disclosure relates to laminates that include patterned microwaveenergy interactive material and may be formed into constructs, such asblanks, cartons, press-formed constructs, packages or the like. Moregenerally, this disclosure relates to laminates that may includepatterned conductive material, wherein the laminates may be used inelectrical/electronic components. This disclosure also relates tosystems and methods for making laminates.

BACKGROUND

Microwave ovens provide a convenient means of cooking and reheating fooditems. Many combinations of materials of different character have beenused in microwave packaging to influence the effect of the microwaveenergy on the food product being heated. These microwave packagingmaterials may be microwave transparent, for example, paper, paperboard,or many plastics, or they may be microwave energy interactive, forexample, metal foils or thin metal deposits. Microwave transparentmaterials generally provide, for example, food product support,packaging form, insulation, and/or vapor barrier functions in packaging.Microwave energy interactive material generally provides, for example,enhanced surface heating, microwave shielding, enhanced microwavetransmission, and/or energy distribution functions in packaging.

Microwave packaging often is created and configured of both microwavetransparent and microwave energy interactive materials. For example,MicroRite brand trays, which are available from Graphic PackagingInternational, Inc., comprise aluminum foil laminated to paperboard. Thealuminum foil is typically configured in predetermined shapes thatdefine a pattern, wherein the shapes/pattern may be formed by chemicallyetching away (in a caustic bath) some of the foil and/or chemicaldeactivation of some of the foil. The configuration of the microwaveenergy interactive material determines performance characteristics ofthe microwave energy interactive material. It may be desirable to havealternatives that are less dependent on caustic chemicals.

As mentioned above, an aspect of this disclosure generally relates tomethods for making laminates that may include patterned conductivematerial, wherein the laminates may be used in electrical/electroniccomponents. When such laminates are made using the Resist/Caustic etchprocess, the conductive metal may be covered with the resist coating,which may impede the attachment of electrical connectors.

SUMMARY

An aspect of this disclosure is the provision of a method of laminating,wherein the method may include forming a frangible laminate comprisingfirst, second and third webs, so that the second web is positionedbetween the first and third webs. The forming of the frangible laminatemay include adhesively bonding a first plurality of sections of thesecond web to the first web, and adhesively bonding a second pluralityof sections of the second web to the third web. Release material may beapplied in order to inhibit at least some of any bonding between thefirst plurality of sections of the second web and the third web. Themethod may further include separating the frangible laminate into afirst laminate and a second laminate, so that the first laminateincludes the first web and the first plurality of sections of the secondweb, and the second laminate includes the third web and the secondplurality of sections of the second web. The separating of the frangiblelaminate into the first and second laminates may be comprised of tearingthe first and second plurality of sections of the second web apart fromone another.

The first web may be referred to as a sacrificial web. The second webmay comprise microwave energy interactive material. The third web may bea substrate comprising a base web. The first plurality of sections ofthe second web may be scrap microwave energy interactive sections. Thesecond plurality of sections of the second web may be retained microwaveenergy interactive sections. The first laminate may be a sacrificiallaminate. The second laminate may be a resultant laminate. The resultantlaminate may be laminated to one or more additional webs or substratesto create a compound laminate that may be used as a packaging materialor any other suitable material.

In the resultant and compound laminates of some embodiments of thisdisclosure, the retained microwave energy interactive sections are atleast partially spaced apart from one another so that gaps arerespectively between the sections, and at least some of the gaps may bein the form of holes in the microwave energy interactive material. Theretained microwave energy interactive sections are bonded to thesubstrate by adhesive material that is positioned between the substrateand the sections. A side of the adhesive material may define both aplurality of protrusions of the adhesive material and a plurality ofrecessed surfaces of the adhesive material. Recessed surfaces of theplurality of recessed surfaces may be respectively positioned betweenprotrusions of the plurality of protrusions. The protrusions of theadhesive material may be respectively in opposing face-to-face contactwith the sections of microwave energy interactive active material.

In the compound laminate, the adhesive material may be a first layer ofadhesive material, and the compound laminate may further include asecond layer of adhesive material. A side of the second layer ofadhesive material may defines both a plurality of protrusions of thesecond layer of adhesive material and a plurality of recessed surfacesof the second layer of adhesive material. Recessed surfaces of theplurality of recessed surfaces of the second layer of adhesive materialmay be respectively positioned between protrusions of the plurality ofprotrusions of the second layer of adhesive material. The protrusions ofthe second layer of adhesive material may respectively extend into gapsbetween the protrusions of the first layer of adhesive material.

The foregoing presents a simplified summary of some aspects of thisdisclosure in order to provide a basic understanding. The foregoingsummary is not extensive and is not intended to identify key or criticalelements of the invention or to delineate the scope of the invention.The purpose of the foregoing summary is to present some concepts of thisdisclosure in a simplified form as a prelude to the more detaileddescription that is presented later. For example, other aspects willbecome apparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not necessarily drawn to scale. They areschematic and exemplary only, and should not be construed as limitingthe invention.

FIG. 1 is a side elevation view of a system for making resultant andcompound laminates that include patterned microwave energy interactivematerial, in accordance with a first embodiment of this disclosure.

FIG. 2 is a side elevation view of a vertical cross section of a portionof a frangible laminate, which is a precursor of the resultant andcompound laminates, in accordance with the first embodiment.

FIG. 3 is a side elevation view of a vertical cross section of a portionof the resultant laminate that has been separated from a remainder ofthe frangible laminate, wherein the remainder of the frangible laminateis a sacrificial laminate, in accordance with the first embodiment.

FIG. 4 is a side elevation view of a vertical cross section of a portionof the sacrificial laminate of the first embodiment.

FIG. 5 is a side elevation view of a vertical cross section of a portionof the compound laminate of the first embodiment.

FIG. 6 is a top pictorial view of a section of the compound laminate ofthe first embodiment.

FIG. 7 is a side elevation view of a vertical cross section of a portionof a compound laminate of a second embodiment.

FIG. 8 is a side elevation view of a vertical cross section of a portionof a compound laminate of a third embodiment.

DETAILED DESCRIPTION

Exemplary embodiments are described below and illustrated in theaccompanying figures, in which like numerals refer to like partsthroughout the several views. The embodiments described provide examplesand should not be interpreted as limiting the scope of the invention.Other embodiments, and modifications and improvements of the describedembodiments, will occur to those skilled in the art and all such otherembodiments, modifications and improvements are within the scope of theinvention.

Referring now in greater detail to FIG. 1, a system 20 and associatedmethods of a first embodiment are described in the following. The system20 and methods may be utilized in the fabrication of a resultantlaminate 21 comprising both microwave transparent and microwave energyinteractive materials. Optionally, the system 20 may be used toincorporate the resultant laminate 21 into a compound laminate 22. Inthe resultant and compound laminates 21, 22, the microwave energyinteractive material is typically configured in predetermined shapesthat define a pattern, so that the shapes/pattern affect theoperativeness of the microwave energy interactive material. The system20 includes numerous stations or stages that are cooperative for causingthe paternization of the microwave energy interactive material. Morespecifically, there are several stages respectively associated withlaminates that are precursors to the resultant laminate 21. For ease ofunderstanding, the precursor laminates may be characterized ascomprising an initial laminate 24, coated laminate 26, and frangiblelaminate 28. In addition, a sacrificial laminate 31 is formed, as willbe discussed in greater detail below.

The initial laminate 24 may be comprised of a continuous web ofsacrificial material 32 and a continuous web of microwave energyinteractive material 34 that are secured together. The sacrificialmaterial 32 may be a disposable substrate. For ease of readability, theweb of sacrificial material 32 may be referred to as a sacrificial web32 in the following. Similarly, the web comprising microwave energyinteractive material 34 may be referred to as an interactive web 34 inthe following. For example, the sacrificial web 32 may be a continuousweb of low-cost, disposable material, such as, but not limited to,paper, or a thin gauge polymer film, for example, a polyethylene film,or any other suitable material, such as a reused or recycled material.For example, the sacrificial web 32 may be in the form of a clear, orsubstantially clear, polymer film through which ultraviolet light, orthe like, may penetrate, as will be discussed in greater detail below.As one example, the sacrificial web 32 may comprise a film withrelatively low thermal stability, such as polyolefin films. Any othersuitable films may be used.

In the first embodiment, the interactive web 34 may be a continuous webof foil, wherein the foil is a thin sheet of metal such as, but notlimited to, aluminum. As a more general example, the interactive web 34may be a web of foil having a thickness sufficient to reflect at least aportion (and up to 100%) of impinging microwave energy. Such webs offoil typically are formed from a conductive, reflective metal or metalalloy, for example, aluminum, copper, stainless steel, silver, gold ornickel, generally having a thickness of from about 0.000285 inches toabout 0.005 inches, for example, from about 0.0003 inches to about 0.003inches. Such webs of foil may more specifically have a thickness of fromabout 0.00035 inches to about 0.002 inches, for example, 0.0016 inches.In one specific example, the interactive web 34 is aluminum foil that isabout 5 microns to about 7 microns thick, or more specifically that is 5microns to 7 microns thick.

The initial laminate 24 may be formed at an upstream laminating stationof the system 20. At the upstream laminating station, the sacrificialand interactive webs 32, 34 are respectively drawn from supply rolls 36,38, such as in response to operation of one or more pairs of nip rollers40, 42, so that the sacrificial and interactive webs 32, 34 are nippedtogether between the upstream nip rollers 42. Prior to the nippingbetween the upstream nip rollers 42, one or more applicators 46 mayapply adhesive material to what will become the inner face of thesacrificial web 32 and/or what will become the inner face of theinteractive web 34. The one or more applicators 46 apply the adhesivematerial in a manner so that there is a predetermined pattern ofadhesive material in the form of adhesive segments 49 (FIG. 2)positioned between the sacrificial and interactive webs 32, 34 in theinitial, coated and frangible laminates 24, 26, 28. Optionally, anysuitable curing and/or drying system 48 may be positioned downstreamfrom the upstream nip rollers 40 for at least aiding in the curingand/or drying of the adhesive segments 49. The adhesive segments 49 arecured and/or dried so that the sacrificial and interactive webs 32, 34are fixedly bonded together. For ease of understanding, adhesivematerials may continue to be referred to as adhesive materials afterthey are cured and/or dried.

Referring to FIG. 2, in the initial, coated and frangible laminates 24,26, 28, the pattern of adhesive segments 49 between the sacrificial andinteractive webs 32, 34 defines both bonded and unbonded areas. Morespecifically, the pattern of adhesive segments 49 between thesacrificial and interactive webs 32, 34 define bonded areas of theinitial laminate 24. Accordingly, in each of the bonded areas, theadjacent surfaces of the sacrificial and interactive webs 32, 34 arebonded together by a respective adhesive segment 49. The adhesivesegments 49 indirectly define the unbonded areas of the initial laminate24 so that, in each of the unbonded areas, the adjacent surfaces of thesacrificial and interactive webs 32, 34 are in opposing face-to-facerelation (e.g., optionally opposing face-to-face contact) with oneanother, but are not bonded to one another. Each of the unbonded areasdefined between the adhesive segments 49 may be in the form of, or maybe generally referred to as, voids 47. Accordingly, in the initiallaminate 24, there are both: sections of the interactive web 34 that arebonded to the sacrificial web 32, and sections of the interactive web 34that are not bonded to the sacrificial web 32. For reasons that willbecome more apparent in the following, the sections of the interactiveweb 34 that are bonded to the sacrificial web 32 may be morespecifically referred to as scrap interactive sections 51, unretainedinteractive sections or discard foil. In contrast, the sections of theinteractive web 34 that are not bonded to the sacrificial web 32 may bereferred to as retained interactive sections 50 or patterned foil, aswill be discussed in greater detail below.

Referring back to FIG. 1, the initial laminate 24 is transformed intothe coated laminate 26 at a coating station. In the coating station, oneor more applicators 52 may apply a release coating to the outer face ofthe interactive web 34. More generally, a release material is applied tothe outer face of the interactive web 34 in a predetermined pattern.

The one or more applicators 52 apply the release coating in a manner sothat there is a predetermined pattern of release coat segments 54 (FIG.2) in each of the coated, frangible and sacrificial laminates 26, 28,31. In the first embodiment, the pattern of the release coat segments 54corresponds or substantially corresponds in shape to, and is superposedwith or substantially superposed with, the pattern of the adhesivesegments 49. More specifically, the resulting release coat segments 54are respectively superposed with or substantially superposed with thescrap interactive sections 51, as discussed in greater detail below.

The release coating, or more specifically the release coat segments 54,may be silicone, such as a silicone that is operative for adhering toaluminum. Optionally, any suitable curing and/or drying system 55 may bepositioned downstream from the applicator(s) 52 for at least aiding inthe curing and/or drying of the release coat segments 54. In the firstembodiment, the cured and/or dried release coat segments 54 arerespectively fixedly bonded to the scrap interactive sections 51.

Optionally, the coated laminate 26 may be kiss or die cut at a diecutting station, and this cutting may be carried out through the use ofany suitable cutting system 56, 58. For example and not for purposes oflimitation, the cutting system 56, 58 is shown in FIG. 1 in the form ofa counter roller 56 and a rotary cutter 58. The coated laminate 26 isdrawn between the counter roller 56 and rotary cutter 58. For example,the rotary cutter 58 may be in the form of a roller with outwardlyprojecting cutting features, such as cutting rules, cutting blades, orany other suitable cutting edges, configured for forming kiss cuts inthe coated laminate 26, wherein the kiss cuts are arranged in a pattern(“kisscut pattern”). The kiss cutting occurs on the side of the coatedlaminate 26 that is defined by the interactive web 34, and the kisscuts, when present, typically extend only partially into the interactiveweb 34.

The kiss cuts may be characterized as being die cuts in the interactiveweb 34, such that the kisscut pattern is defined by the die cuts. Eachof the die cuts may be more generally referred to as a line ofseparation such as, but not limited to, a cut (e.g., slit), cut line,tear line, line of spaced apart cuts (e.g., perforations), and/or thelike. The kisscut pattern/die cuts in the interactive web 34 may beformed in any suitable manner, such as with one or more rotary dies,flat dies, lasers, and/or the like. However and at least in theory andperhaps preferably (e.g., optionally), the cutting system 56, 58 may beomitted and the die cuts may be totally replaced with tears, or morespecifically tearing that occurs in the interactive web 34 when thesacrificial laminate 31 is separated from the resultant laminate 28, aswill be discussed in greater detail below. On the other hand, thecutting or scoring system 56, 58 may be configured for kisscutting orscoring the interactive web 34 in a manner that helps to facilitate thepredetermined tearing that occurs in the interactive web 34 when theintermediate and sacrificial laminates 21, 31 are separated from oneanother, as will be discussed in greater detail below.

The kisscut pattern, kiss cuts, scores, die cuts and/or tears in theinteractive web 34 are cooperatively configured with the positions ofthe adhesive segments 49 and release coat segments 54 for at leastpartially further defining the retained and scrap interactive sections50, 51 of the interactive web 34. For ease of description, the kisscutpattern, kiss cuts, scores, die cuts and/or tears in the interactive web34 may be generally referred to as “lines of disruption”, and anysuitable lines of disruption may be incorporated into the interactiveweb 34 at any suitable time for facilitating manufacture of theintermediate and sacrificial laminates 21, 31. At least when thesacrificial laminate 31 is separated from the resultant laminate 28, thelines of disruption in the interactive web 34 respectively separate theretained and scrap interactive sections 50, 51 of the interactive web 34from one another. More specifically, the lines of disruption in theinteractive web 34 are respectively arranged between the retained andscrap interactive sections 50, 51 such that each of the retainedinteractive sections 50 is substantially circumscribed by the respectiveline of disruption, for allowing the retained and scrap interactivesections 50, 51 to be separated from one another, as will be discussedin greater detail below.

Referring to FIG. 1, a frangible laminate 28 is formed at anintermediate laminating station of the system 20. The frangible laminate28 comprises the coated laminate 26 and a web of a supporting substrateor base material 62 that are secured together. For ease of readability,the web of base material 62 may be referred to as a base web 62 in thefollowing. For example, the base web 62 may be a continuous web of anysuitable supporting substrate such as, but not limited to, a polymerfilm (e.g., polypropylene film or polyester film), a susceptor film asdiscussed in greater detail below, paper and/or paperboard. For example,the base web 62 may be suitable for being formed into constructs suchas, but not limited to, blanks, cartons, trays, bowls, press-formedconstructs, packages, or the like. As shown in FIG. 6, when the basematerial 62 is a clear or substantially clear substrate, optionallygraphics 63 may be printed (e.g., reverse printed) onto what will becomethe inner surface of the base web 62 prior to the base web beinglaminated to the coated laminate 26. The base web 62 with or without thegraphics 63 may be generally referred to as a substrate. As one example,the base web 62 may comprise a film with relatively low thermalstability, such as polyolefin films. Any other suitable films may beused.

As shown in FIG. 1, the base web 62 is drawn from a supply roll 64, suchas in response to operation of one or more pairs of nip rollers 66, 68,so that the coated laminate 26 and base web 62 are nipped togetherbetween the intermediate nip rollers 68. Prior to the nipping betweenthe intermediate nip rollers 68, one or more applicators 70 apply asubstantially continuous layer of adhesive material 71 (FIG. 2) to whatwill become an inner face of the coated laminate 26 and/or what willbecome the inner face of the base web 62. In the first embodiment, theapplicator(s) 70 apply the adhesive material 71 to the entire (e.g.,substantially the entire) inner face of the coated laminate 26 and/orthe inner face of the base web 62. That is, the applicator(s) 70typically apply a continuous flood coating of the adhesive material 71to the inner face of the coated laminate 26 and/or the inner face of thebase web 62. The substantially continuous layer of adhesive material 71may be referred to as an adhesive coat 71.

Optionally, any suitable curing and/or drying system 72 may bepositioned downstream from the intermediate nip rollers 68 for at leastaiding in the curing and/or drying of the adhesive coat 71. The adhesivecoat 71 is cured and/or dried so that the retained interactive sections50 are fixedly bonded to the base web 62.

The release coat segments 54 are configured and effective so that theretained interactive sections 50 will become fixedly bonded to the baseweb 62, and the scrap interactive sections 51 do not, or more generallysubstantially do not, become bonded to the base web 62. The release coatsegments 54 are operative for inhibiting at least some of any bondingbetween the scrap interactive sections 51 and the base web 62.

Referring to FIG. 2, the adhesive segments 49, adhesive coat 71 andrelease coat segments 54 of the frangible laminate 28 are cooperativefor defining both bonded and unbonded areas in the frangible laminate28. More specifically, the scrap interactive sections 51 are fixedlybonded to the sacrificial web 32 and not bonded (e.g., substantially notbonded) to the base web 62. In contrast, the retained interactivesections 50 are fixedly bonded to the base web 62 and not bonded (e.g.,substantially not bonded) to the sacrificial web 32.

With continued reference to FIG. 2, the adhesive coat 71 and releasecoat segments 54 of the frangible laminate 28 are cooperative so that aside of the adhesive coat 71 includes recessed surfaces 71R respectivelybetween protrusions 71P of the adhesive coat 71. The protrusions 71 Prespectively extend into gaps between the release coat segments 54 andare in opposing face-to-face contact with the retained interactivesections 50. The release coat segments 54 respectively extend into gapsbetween the protrusions 71P and are in opposing face-to-face contactwith the recessed surfaces 71R.

Referring to FIG. 1, the resultant laminate 21 (FIG. 3) is extracted ata stripping, separating or delamination station of the system 20. Morespecifically, the frangible laminate 28 (FIG. 2) is separated ordelaminated (e.g., divided) into parts comprising the resultant laminate21 (FIG. 3) and the sacrificial laminate 31 (FIG. 4) at the separatingor delaminating station of the system 20. The resultant laminate 21 maybe formed from the frangible laminate 28 (FIG. 2) by separating ordelaminating the sacrificial web 32, adhesive segments 49, scrapinteractive sections 51 and release coat segments 54 from a remainder ofthe frangible laminate 28, wherein the resultant laminate 21 is theremainder of the frangible laminate 28. More specifically, thesacrificial laminate 31 (FIG. 4) (which comprises the sacrificial web32, adhesive segments 49, scrap interactive sections 51 and release coatsegments 54) is stripped or delaminated from the resultant laminate 21.During the separating, the release material, or more specifically therelease coat segments 54, at least partially cause adhesive bond failurebetween the scrap interactive sections 51 and the base web 62.

For example, the sacrificial laminate 31 may be stripped by drawing thesacrificial laminate around one or more rollers 74, 76, and forming thesacrificial laminate into a roll 78. The roll 78 may be characterized asbeing schematically illustrative of a conventional winding apparatus forforming the sacrificial laminate 31 into a roll. The retainedinteractive sections 50 remain secured to the base web 62 by way of atleast the adhesive coat 71, or by way of any other suitable arrangementof adhesive material, so that the resultant laminate 21 comprises thebase web 62 with retained interactive sections 50 fixedly securedthereto. In one example, substantially all of the release coat or agent54 may be removed with the sacrificial laminate 31, so that theresultant laminate 21 is substantially absent of any of the release coator agent 54, as will be discussed in greater detail below.

Optionally, the side of the resultant laminate 21 with the exposedretained interactive sections 50 may be smoothed, or more specificallythe exposed faces of the retained interactive sections 50 may besmoothed, such as through the use of brushes or other suitable smoothingdevices, to remove any rough edges of the retained interactive sections.For example and optionally, rough edges may be formed when the scrapinteractive sections 51 are torn away from the retained interactivesections 50.

Further regarding the tearing between scrap interactive sections 51 andthe retained interactive sections 50, it is believed that the frangiblelaminate 28 being separated into the resultant and sacrificial laminates21, 31 may be comprised of at least one scrap interactive section 51 andat least one retained interactive section 50 being torn apart from oneanother prior to any cutting in the interactive web 34 between the atleast one interactive section 51 and the at least one retainedinteractive sections 50. More specifically, it is believed that thefrangible laminate 28 being separated into the resultant and sacrificiallaminates 21, 31 may be comprised of each of the plurality of scrapinteractive section 51 and each of the plurality of retained interactivesections 50 being respectively torn apart from one another prior to anycutting in the interactive web 34 therebetween. Accordingly andreiterating from above, it is believed that the cutting of theinteractive web 34 at the cutting system 56, 58 is optional and may beomitted. Alternatively, the system 10 may include and use the cuttingsystem 56, 58 as discussed above.

The sacrificial laminate 31 (FIG. 4) may be discarded, reused, recycled,or the like. Optionally, immediately after the resultant and sacrificiallaminates 21, 31 are separated from one another, the resultant laminate21 (FIG. 3) may be formed into a roll, such as by using a conventionalwinding apparatus. Thereafter, the resultant laminate 21 may be unwoundfrom its roll and used in the manufacture of items that comprise theresultant laminate. In addition and/or alternatively, the resultantlaminate 21 may be used in any suitable manner, such as in theconstruction of an article, construct, package, or the like, comprisingmicrowave energy interactive material (e.g., the retained interactivesections 50). For example, the resultant laminate 21 may be printedupon; laminated to another substrate that may comprise paper,paperboard, polymeric film and/or microwave energy interactive material;die cut; formed into and/or incorporated into constructs such as, butnot limited to, containers, pouches, bags, sleeves, blanks, cards,cartons, trays, bowls, press-formed constructs, injection-moldedconstructs, packages and/or the like.

In the first embodiment shown in FIG. 1, rather than being formed into aroll, the resultant laminate 21 is incorporated into the compoundlaminate 22 (FIGS. 5-7) at a downstream laminating station of the system20. The compound laminate 22 comprises the resultant laminate 21 and atleast one additional substrate that are secured together, wherein theadditional substrate may be in the form of a continuous web of coveringmaterial 84. For ease of readability, the web of covering material 84may be referred to as a covering web 84 in the following. For example,the covering web 84 may be a barrier layer of material such as polymerfilm, or more specifically a polyethylene terephthalate film, or anyother suitable material. As a more specific example, the covering web 84may be a suitable conventional polymeric sealant film, and it may serveas a food contact surface of a pouch or other construct formed from thecompound laminate 22. As another example, the covering web 84 maycomprise a film with relatively low thermal stability, such aspolyolefin films. Any other suitable films may be used.

In the system 20 shown in FIG. 1, the covering web 84 is drawn from asupply roll 86, such as in response to operation of one or more pairs ofnip rollers 88, 90, so that the resultant laminate 21 and covering web84 are nipped together between the downstream nip rollers 90. Prior tothe nipping between the downstream nip rollers 90, one or moreapplicators 92 apply a substantially continuous layer of adhesivematerial 93 (FIG. 5) to what will become an inner face of the resultantlaminate 21 and/or what will become the inner face of the cover web 84,so that the cover web will become broadly, securely adhered or bonded tothe resultant laminate to form the compound laminate 22. In the firstembodiment, the applicator(s) 92 apply the adhesive material 93 to theentire (e.g., substantially the entire) inner face of the resultantlaminate 21 and/or the inner face of the cover web 84. That is, theapplicator(s) 92 typically apply a flood coating of the adhesivematerial 93 to the inner face of the resultant laminate 21 and/or theinner face of the cover web 84. The substantially continuous layer ofadhesive material 93 may be referred to as an adhesive coat 93. Theadhesive material supplied from the applicator(s) 92 is dried and/orcured so that the resultant laminate 21 and covering web 84 are fixedlybonded together. If necessary or desired, a curing and/or drying systemmay be provided for drying and/or curing the adhesive coat 93. Thecompound laminate 22 may be formed into a roll 94, and thereafter drawnfrom the roll and formed into constructs, packages, or the like. Theroll 94 may be characterized as being schematically illustrative of aconventional winding apparatus for forming the compound laminate 22 intoa roll.

With continued reference to FIG. 5, the adhesive coat 93, retainedinteractive sections 50 and adhesive coat 71 are cooperative so that aside of the adhesive coat 93 includes recessed surfaces 93R respectivelybetween protrusions 93P of the adhesive coat 93. The protrusions 93Pextend into gaps respectively between compound protrusions, wherein eachcompound protrusion includes a retained interactive section 50 and aprotrusion 71P of the adhesive coat 71. The protrusions 93P arerespectively in opposing face-to-face contact with the recessed surfaces71R of the adhesive coat 71. The retained interactive sections 50 andprotrusions 71P respectively extend into gaps between the protrusions93P so that the retained interactive sections 50 are respectively inopposing face-to-face contact with the recessed surfaces 93R.

In accordance with the first embodiment, each gap between compoundprotrusions includes a gap between retained interactive sections 50 thatare at least partially spaced apart from one another. That is, theretained interactive sections 50 of the first embodiment are at leastpartially spaced apart from one another so that gaps are respectivelybetween the retained interactive sections 50, and at least some of thesegaps may be in the form of holes 106 (FIG. 6) in the microwave energyinteractive material.

The compound laminate 22 may be formed into constructs or other suitablepackages or articles in any suitable manner. For example, the compoundlaminate 22 may be formed into and/or incorporated into constructs suchas, but not limited to, containers, pouches, bags, sleeves, blanks,cards, cartons, trays, bowls, press-formed constructs, injection-moldedconstructs, packages and/or the like. Accordingly, the resultant andcompound laminates 21, 22 may be referred to as packaging materials thatmay be used as wraps, containers, pouches, bags, sleeves, blanks, cards,cartons, trays, bowls, press-formed constructs, injection-moldedconstructs, packages and/or the like in association with food beingprocessed in a microwave oven, or the like.

The adhesive segments 49 and the more extensive adhesive coats 71, 93may be formed from any suitable adhesive materials such as, but notlimited to, electron beam curable (“EB-curable”) adhesive material,ultraviolet-curable (“UV-curable”) adhesive material, solvent-basedadhesive material and/or water-based adhesive material. As a morespecific example, suitable UV-curable adhesive materials may utilize orotherwise incorporate cationic UV-cure technology. For example and ascompared to some other adhesive materials, the cationic UV-curableadhesive material may adhere more strongly to the microwave energyinteractive material 34, such as when the microwave energy interactivematerial is aluminum, or the like. On the other hand and regarding theoption of using an adhesive material that may not adhere as well asdesired to another layer, one or more suitable tie layers may bepositioned between the adhesive layer and the other layer. Moregenerally in this regard, a variety of criteria may be used to selectsuitable adhesive materials and other features of the laminates. Forexample, when the resultant and compound laminates 21, 22 may be used inpackaging for food, typically the adhesive coats 71, 93 and othercomponents of the resultant and compound laminates will comply withrelevant regulations for food packaging materials.

The release coat segments 54 may be formed from any suitable releasecoat material, such as, but not limited to, silicone that is operativefor adhering to aluminum. The silicone may be an EB-curable, UV-curableand/or thermally curable silicone material. The applicators 46, 52, 70,92 may be any suitable applicators such as, but not limited to,patterned roll-on applicators; patterned stamp applicators; movable,computer-controlled nozzle applicators; rotogravure printing presses;flexographic printing presses and/or any other suitable types ofapplicator mechanisms. Optionally, any suitable curing and/or dryingsystems 48, 55, 72 may be provided for at least partially curing and/ordrying the substances that form the adhesive segments 49, release coatsegments 54, and adhesive coats 71, 93.

Depending upon the adhesive material used, the curing and/or dryingsystems 48, 55, 72 may be sources of heat such as drying or curingovens, EB sources and/or UV light sources. For example, the sacrificialweb 32 may be a clear, or substantially clear, polymer film; theadhesive segments 49 may be formed from UV-curable material; and thecuring system 48 may comprise at least one source of UV light forshining the UV light through the sacrificial web to the adhesivesegments 49, or the like. Similarly, the base web 62 may be a clear, orsubstantially clear, polymer film; the adhesive coat 71 may be formedfrom UV-curable material; and the curing system 72 may comprise at leastone source of UV light for shining the UV light through the sacrificialweb to the adhesive coat 71, or the like. Similarly, the covering web 84may be a clear, or substantially clear, polymer film; the adhesive coat93 may be formed from UV-curable material; and a curing system maycomprise at least one source of UV light for shining the UV lightthrough the covering web 84 to the adhesive coat 93, or the like. Othersuitable adhesive materials, applicators, curing systems and/or dryingsystems may be used. In one aspect of this disclosure, any of thepolymer films may be a film with relatively low thermal stability, suchas polyolefin films. Any other suitable films may be used.

In the first embodiment, the retained interactive sections 50 (FIGS. 2,3 and 5) are microwave energy reflecting (or reflective) elements. Inthis regard, each of the retained interactive sections 50 may beconfigured as a shield that restricts (e.g., substantially restricts)the passage of microwave energy therethrough. Retained interactivesections 50 configured as shielding may be used be used in situationswhere a food item associated therewith is prone to scorching or dryingout during heating in a microwave oven. In other cases, the retainedinteractive sections 50 may be in the form of smaller microwave energyreflecting elements that may be used to diffuse or lessen the intensityof microwave energy. One example of a material utilizing such microwaveenergy reflecting elements is commercially available from GraphicPackaging International, Inc. (Marietta, Ga.) under the trade nameMicroRite® packaging material. In other examples, a plurality ofmicrowave energy reflecting elements (e.g., retained interactivesections 50) may be configured to form a microwave energy distributingelement to direct microwave energy to specific areas of a food itemassociated therewith. If desired, retained interactive sections 50 maybe configured as loops of a length that causes microwave energy toresonate (e.g., a resonating patch antenna), thereby enhancing thedistribution effect, as discussed in greater detail below.

As at least partially discussed above, each scrap interactive section 51may be substantially superposed with both a respective adhesive segment49 and a respective release coat segment 54. At least in theory, foreach scrap interactive section 51 and the respective segments 49, 54substantially superposed therewith, the superposition may be exact; thesuperposition may be close to being exact, such as by there being anoffset of about 0.001 inch; or there may be any other suitablevariations in the superposition. For example, for each scrap interactivesection 51 and the respective segments 49, 54 substantially superposedtherewith, one or more of these features may be slightly larger orslightly smaller in diameter than other(s) of these features. As anotherexample, for each scrap interactive section 51 and the respectivesegments 49, 54 substantially superposed therewith, one or more of thesefeatures may be shaped slightly differently than other(s) of thesefeatures, such as a result of at least some of these features havingdifferent lengths in the machine direction.

Theoretically and in accordance with one aspect of the first embodiment,the possible offsets, variations in size and/or variations in shapebetween the scrap interactive section 51 and the respective segments 49,54, or the like, may be tailored in a predetermined manner that seeks tocontrol and/or compensate for variations in the tearing of the microwaveenergy interactive material 34 that at least partially (e.g.,substantially) defines and separates the retained and scrap interactivesections 50, 51 from one another during the stripping apart of theresultant and sacrificial laminates 21, 31 in the system 20.Alternatively or additionally, the possible offsets, variations in sizeand/or variations in shape may result from any unevenness and/orvariability in the tearing of the microwave energy interactive material34 that at least partially (e.g., substantially) defines and separatesthe retained and scrap interactive sections 50, 51 from one another.

Any unevenness, variability and/or other attributes associated with thetearing of the microwave energy interactive material 34 may depend atleast in part upon the speed of operation of the system 20, otheroperational characteristics and/or the characteristics of the materialsused in the system. Accordingly and at least in theory, the operationalcharacteristics of the system 20 and the characteristics of thematerials used in the system may be selected and adjusted in an effortto control any unevenness, variability and/or other attributesassociated with the tearing of the microwave energy interactive material34. Accordingly and depending, for example, upon allowable tolerances inthe resultant or compound laminates 21, 22 or constructs incorporatingthem, other variations in the superpositioning may be acceptable and arewithin the scope of this disclosure.

As mentioned above, the resultant and compound laminates 21, 22 may bereferred to as packaging materials that may be used as wraps,containers, pouches, bags, sleeves, blanks, cards, cartons, trays,bowls, press-formed constructs, injection-molded constructs, packagesand/or the like in association with food being processed in a microwaveoven, or the like. Rather than forming these packaging materials 21, 22into rolls (e.g., roll 94 in FIG. 1), the system 20 may further includeprocessing equipment (e.g., one or more additional dies) for forming thepackaging materials into final constructs such as, but not limited to,carton blanks, press-formed constructs, or the like. That is, anyadditional suitable processing stations may be included in the system,such as at positions proximate the downstream end of the system 20.

FIG. 6 schematically illustrates a lengthwise section of the compoundlaminate 22 and provides an example of one of the numerous possibleconfigurations or patterns of the retained interactive sections 50. InFIG. 6, the covering web 84 (FIGS. 1 and 5) is facing upward andtransparent, so that the retained interactive sections 50 are seenthrough the transparent covering web. In FIG. 6, the retainedinteractive sections 50 are shaped to form first and second sections152, 252 of the retained interactive sections 50. The first section 152of the retained interactive sections 50 or the second sections 252 ofthe retained interactive sections 50 may be omitted and/or configureddifferently than shown in FIG. 6.

As shown in FIG. 6, the first section 152 of the retained interactivesections 50 is in the form of a metal foil band including somewhatrounded corners 104 and obround holes 106 in or between the respectiveretained interactive sections 50, wherein the holes are in a spacedapart configuration. As used in this Detailed Description section ofthis disclosure, the term “obround” refers to a shape substantiallyconsisting of two semicircles connected by parallel lines tangent totheir endpoints. The first section 152 of the retained interactivesections 50 may be referred to as a microwave energy reflecting (orreflective) element that may be used as a shielding element when anassociated food item is prone to scorching or drying out during heatingin a microwave oven. More specifically, at least portions of theretained interactive sections 50 together with the holes 106 may becooperative, such as for diffusing or lessening the intensity ofmicrowave energy, such as when these features are parts of upright wallsof a tray. One example of a material utilizing a combination of suchmicrowave energy reflecting and transparent elements is commerciallyavailable from Graphic Packaging International, Inc. (Marietta, Ga.)under the trade name MicroRite® packaging material.

The second sections 252 of the retained interactive sections 50 are inthe form of metal foil sections 110 arranged in clusters in alattice-like configuration. The first section 152 of the retainedinteractive sections 50 is spaced from and forms a border around thesecond sections 252 of the retained interactive sections 50. The secondsections 252 of the retained interactive sections 50 may comprise aplurality of microwave energy reflecting elements arranged to form amicrowave energy distributing element that is operative for directingmicrowave energy to specific areas of an associated food item. Ifdesired, the loops defined by the second sections 252 of the retainedinteractive sections 50 may be of a length that causes microwave energyto resonate (e.g., a resonating patch antenna), thereby enhancing thedistribution effect. Examples of microwave energy distributing elementsare described in U.S. Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and6,677,563, each of which is incorporated by reference in its entirety.

Referring back to FIG. 5, the covering web 84 may be a barrier layer ofmaterial such as polymer film that may serve as a food contact surfaceof a construct, such as a container or package, formed from the compoundlaminate 22 of the first embodiment. As another example, the coveringweb 84 may be a polymer film suitable for use in insert molding, such asin-mold labeling. Accordingly, when the covering web 84 is a clear orsubstantially clear substrate, graphics may be printed (e.g., reverseprinted) onto what will become the inner surface of the covering web 84prior to the covering web being laminated to the resultant laminate 21.Alternatively, the covering web 84 and adhesive coat 93 may be replacedwith a coating suitable for use in insert molding, such as in-moldlabeling. Optionally, the base web 62 may serve as a food contactsurface of the construct formed from, or otherwise including, thecompound laminate 22.

A second embodiment is like the first embodiment, except for variationsnoted and variations that will be apparent to one of ordinary skill inthe art. Referring to FIG. 7, the covering web 84 of the secondembodiment may comprise, consist essentially of, or consist of paper orpaperboard. The paper or paperboard may be coated, printed or otherwiseprocessed in a conventional manner. For example, graphics 95 may beprinted onto the outer surface of the covering web 84. Optionally, thebase web 62 may serve as a food contact surface of the construct orpackage formed from, or otherwise including, the compound laminate 22.The paper may have a basis weight of from about 15 to about 60 lb./ream(lb./3000 sq. ft.), for example, from about 20 to about 40 lb./ream, forexample, about 25 lb./ream. The paperboard may have a basis weight offrom about 60 to about 330 lb./ream, for example, from about 80 to about200 lb./ream. The paperboard generally may have a thickness of fromabout 6 to about 30 mils, for example, from about 12 to about 28 mils.In one particular example, the paperboard has a thickness of about 20mils (0.020 inches). Any suitable paperboard may be used, for example, asolid bleached sulfate board, for example, Fortress® board, commerciallyavailable from International Paper Company, Memphis, Tenn., or solidunbleached sulfate board, such as SUS® board, commercially availablefrom Graphic Packaging International.

In the laminates of this disclosure, one or more of the layers or websmay be omitted, arranged differently, incorporated in a different orderand/or other layers or webs may be included. For example, the laminatesof this disclosure may further include one or more tie layers, as atleast alluded to above.

As another example, a third embodiment is like the second embodiment,except for variations noted and variations that will be apparent to oneof ordinary skill in the art. According to the third embodiment andreferring to FIG. 1, prior to the base web 62 being laminated to theinitial laminate 24, microwave energy interactive material (“MEIM”) ismounted to the base web 62. Accordingly, the base web 62 and the MEIMmounted thereto may be a laminate, wherein the base web 62 may be asubstrate that is transparent to microwave energy, and the base web 62including the MEIM mounted thereto may collectively be in the form of asusceptor or susceptor film.

The MEIM, which is mounted to the base web 62 prior to the base web 62being laminated to the initial laminate 24, may be discontinuous, suchas for achieving a desired heating effect for a food item associatedwith the third embodiment's compound laminate 22 (FIG. 8). For exampleand referring to FIG. 8, the MEIM may be discontinuous by virtue of theMEIM defining patterns, such as a pattern of effective MEIM segments 98,and a pattern of removed (e.g., substantially removed) or deactivated(e.g., substantially deactivated) MEIM segments 99. The deactivated MEIMsegments 99 are typically transparent to (e.g. substantially transparentto) microwave energy.

As best understood with reference to FIG. 8, in the compound laminate 22of the third embodiment, the pattern of the deactivated MEIM segments 99may correspond or substantially correspond in shape to, and may besuperposed with or substantially superposed with, the pattern of theretained interactive sections 50. More specifically, the deactivatedMEIM segments 99 may be respectively superposed with or substantiallysuperposed with retained interactive sections 50. As a more specificexample, each deactivated MEIM segment 99 may be substantiallysuperposed with (e.g., may not be exactly superposed with) a respectiveretained interactive section 50 as a result of the deactivated MEIMsegment 99 having a diameter that is slightly larger than the diameterof the respective retained interactive section 50. Accordingly, in thethird embodiment, like other embodiments, the disclosed superposed orsubstantially superposed relationships may vary in any suitable manner.

In the third embodiment's frangible laminate 28 (FIG. 1), the pattern ofthe effective MEIM segments 98 may correspond or substantiallycorrespond in shape to, and may be superposed with or substantiallysuperposed with, the pattern of the scrap interactive sections 51 (FIGS.2 and 4). More specifically, the effective MEIM segments 98 may berespectively superposed with or substantially superposed with scrapinteractive sections 51. As a more specific example, each effective MEIMsegment 98 may be substantially superposed with (e.g., may not beexactly superposed with) a respective scrap interactive section 51 as aresult of the effective MEIM segment 98 having a diameter that isslightly smaller than the diameter of the respective scrap interactivesection 51. Reiterating from above, the disclosed superposed orsubstantially superposed relationships may vary in any suitable manner.

As a more specific example regarding the base web 62 of the thirdembodiment, the base web 62 of the third embodiment may be transparentto microwave energy, and the MEIM may be a layer of aluminum. The baseweb 62 may be a polymeric film 62. The polymeric film 62 may comprise,consist of or consist essentially of polyethylene terephthalate, and thelayer of aluminum is typically sufficiently thin so that it is operativefor absorbing at least a portion of impinging microwave energy andconverting it to thermal energy (i.e., heat) through resistive losses inthe layer of aluminum. Accordingly, the polymeric film 62 together withthe effective MEIM segments 98 of the third embodiment together are inthe form of or comprise a susceptor film.

In one example of a method for forming the susceptor film into thepatterned susceptor film including both the effective MEIM segments 98and the deactivated MEIM segments 99, a rotogravure printing press maybe used to apply a pattern of a caustic liquid, such as a liquidcontaining about 50% sodium hydroxide, to a continuous layer of thealuminum (“precursor aluminum”) that was previously mounted to and isbeing carried by the base web 62. The pattern of caustic liquid may beapplied by any suitable types of coaters, such as a flexographicprinting press. The caustic liquid may be applied in the same patternthat is intended to be defined by the deactivated MEIM segments 99. Thecaustic liquid reacts with and deactivates the respective portion of thealuminum by converting it to aluminum oxide, wherein the deactivatedMEIM segments 99 are the aluminum oxide. The aluminum oxide isrelatively transparent to light as compared to pure aluminum. In furthercontrast to aluminum, aluminum oxide is an electrical insulator that istransparent to microwave energy. The base web 62 may then be laminatedto the initial laminate 24 as discussed above, so that effective MEIMsegments 98 are respectively superposed with or substantially superposedwith scrap interactive sections 51, and the deactivated MEIM segments 99are respectively superposed with or substantially superposed withretained interactive sections 50.

In another example of a method for forming the susceptor film into thepatterned susceptor film including both the effective MEIM segments 98and the deactivated MEIM segments 99, a rotogravure printing press maybe used to apply a pattern of a resist coating to a continuous layer ofthe aluminum (“precursor aluminum”) that was previously mounted to andis being carried by the base web 62. The pattern of resist coating maybe applied by any suitable types of coaters, such as a flexographicprinting press. The resist coating is applied in the same pattern thatis intended to be defined by the effective MEIM segments 98. After theresist coating is dried and/or cured, the base web 62 may be drawnthrough a caustic bath, such as a caustic bath of 50% sodium hydroxide.

The resist coating is resistant to the caustic bath so that the causticbath does not react with the protected portion of the aluminum, whereinthe protected portion of the aluminum is superposed with the resistcoating, and the effective MEIM segments 98 are the protected portion ofthe aluminum. In contrast, the caustic bath reacts with the unprotectedportion of the aluminum, wherein the unprotected portion of the aluminumis not superposed with the resist coating. The caustic bath deactivatesthe unprotected portion of the aluminum by converting it to aluminumoxide, wherein the deactivated MEIM segments 99 are the aluminum oxide.The aluminum oxide is relatively transparent to light as compared topure aluminum. In further contrast to aluminum, aluminum oxide is anelectrical insulator that is transparent to microwave energy.

In accordance with the above-discussed method, the base web 62 may berinsed with water immediately after the base web 62 is drawn out of thecaustic bath. The base web 62 may then be laminated to the initiallaminate 24 as discussed above, so that effective MEIM segments 98 arerespectively superposed with or substantially superposed with scrapinteractive sections 51, and the deactivated MEIM segments 99 arerespectively superposed with or substantially superposed with retainedinteractive sections 50.

Examples of discontinuous MEIM (e.g., patterns of effective anddeactivated MEIM segments 98, 99) and associated manufacturing methodsare disclosed in U.S. Pat. Nos. 6,765,182; 6,717,121; 6,677,563;6,552,315; 6,455,827; 6,433,322; 6,414,290; 6,251,451; 6,204,492;6,150,646; 6,114,679; 5,800,724; 5,759,422; 5,672,407; 5,628,921;5,519,195; 5,424,517; 5,410,135; 5,354,973; 5,340,436; 5,266,386;5,260,537; 5,221,419; 5,213,902; 5,117,078; 5,039,364; 4,963,424;4,936,935; 4,890,439; 4,775,771; 4,865,921; and Re. 34,683, each ofwhich is incorporated herein by reference in its entirety. For example,U.S. Pat. No. 4,865,921 discloses that its inactivating chemical isprinted directly onto the selected area or areas of the microwaveinteractive layer, and that the inactivating chemical dries in placeafter if converts the selected area into an inactivated area. Morespecifically, the microwave interactive film is dried after printingwith the inactivating chemical, without washing away the inactivatingchemical or the inactivated material of the microwave interactive layer.

Further regarding the above-discussed MEIMs (e.g., effective MEIMsegments 98), a susceptor is or comprises a thin layer of MEIM thattends to absorb at least a portion of impinging microwave energy andconvert it to thermal energy (i.e., heat) through resistive losses inthe layer of MEIM. The MEIM may comprise an electroconductive orsemiconductive material, for example a vacuum deposited metal or metalalloy, or a metallic ink, an organic ink, an inorganic ink, a metallicpaste, an organic paste, an inorganic paste or any combination thereof.Examples of metals and metal alloys that may be suitable include, butare not limited to, aluminum, chromium, copper, inconel alloys(nickel-chromium-molybdenum alloy with niobium), iron, magnesium,nickel, stainless steel, tin, titanium, tungsten, and any combination oralloy thereof. Typical susceptors comprise aluminum, generally less thanabout 500 angstroms in thickness, for example, from about 60 to about100 angstroms in thickness, and having an optical density of from about0.15 to about 0.35, for example, about 0.17 to about 0.28.

Alternatively, the MEIM (e.g., effective MEIM segments 98) may comprisea suitable electroconductive, semiconductive, or non-conductiveartificial dielectric or ferroelectric. Artificial dielectrics compriseconductive, subdivided material in a polymeric or other suitable matrixor binder, and may include flakes of an electroconductive metal, forexample, aluminum.

In other embodiments, the MEIM (e.g., effective MEIM segments 98) may becarbon-based, for example, as disclosed in U.S. Pat. Nos. 4,943,456,5,002,826, 5,118,747, and 5,410,135.

MEIMs (e.g., effective MEIM segments 98) may be combined with polymerfilms (e.g., base web 62), such as to create microwave susceptorstructures that may be referred to as susceptor films. Such polymerfilms (e.g., base web 62) may be clear, translucent, or opaque, asneeded for a particular application. The thickness of the film maytypically be from about 35 gauge to about 10 mil. In one aspect, thethickness of the film is from about 40 to about 80 gauge. In anotheraspect, the thickness of the film is from about 45 to about 50 gauge. Instill another aspect, the thickness of the film is about 48 gauge.Examples of polymeric films that may be suitable include, but are notlimited to, polyolefins, polyesters, polyamides, polyimides,polysulfones, polyether ketones, cellophanes, or any combinationthereof. Other non-conducting substrate materials such as paper andpaper laminates, metal oxides, silicates, cellulosics, or anycombination thereof, also may be used.

According to one aspect of this disclosure, the polymeric film (e.g.,base web 62) may comprise polyethylene terephthalate. Examples ofpolyethylene terephthalate film that may be suitable for use as theprimary substrate include, but are not limited to, MELINEX®,commercially available from DuPont Teijan Films (Hopewell, Va.), andSKYROL, commercially available from SKC, Inc. (Covington, Ga.).Polyethylene terephthalate films are used in commercially availablesusceptors, for example, the QWIK WAVE® Focus susceptor and theMICRO-RITE.® susceptor, both available from Graphic PackagingInternational (Marietta, Ga.).

The above-disclosed patterns (e.g., of the effective and deactivatedMEIM segments 98, 99) are provided as examples only, and other patternsare within the scope of this disclosure. For example, one or more of theabove-discussed patterns (e.g., of the effective and deactivated MEIMsegments 98, 99) may be tailored to the desired end uses of theresultant and compound laminates 21, 22.

In accordance with one aspect of this disclosure, the metal foil pattern(e.g., the pattern of the retained interactive sections 50) may beproduced without using chemical etching or die cutting. Therefore,laminates of this disclosure may be produced without there being causticchemicals to dispose of, and without there being cutting dies which wearand require replacement.

In one aspect of this disclosure, the laminates may include thin filmshaving relatively low thermal stability, such as polyolefin films.

One aspect of this disclosure is the provision of a method that enablesthe manufacture of pattern metal foils (e.g., the pattern of theretained interactive sections 50) registered to pattern etched microwavesusceptors (e.g., the pattern of effective MEIM segments 98), whereinall operations (e.g., substantially all operations) may be combined on asingle printing and laminating press.

In one aspect of this disclosure, combined use of pattern appliedadhesive 49 and pattern applied release coat 54 on opposite sides of ametal foil 50, 51 enables a stripping mechanism to create a resultantpattern foil laminate 21.

In one aspect of this disclosure, none (e.g., substantially none) of thesilicone release coat or agent 54 remains on the resultant pattern foillaminate 21, which seeks to enhance further converting of the resultantlaminate 21 into a finished packaging article. In one specific exampleand at least in theory, all or substantially all of the release coat oragent 54 may be retained by the sacrificial laminate 31, such that itmay not be necessary for the release coat or agent to comply withregulations for food packaging materials. In an alternative embodiment,the release coat or agent 54 may be omitted and the adhesive material 71may be applied in a pattern so that only the protrusions 71P of theadhesive coat 71 are present (e.g., the recessed surfaces 71R of theadhesive coat 71 are omitted). That is, in this alternative embodimentthe adhesive material 71 is not applied in a continuous flood coating.

According to one aspect of this disclosure, paper or paperboardsubstrates are not required to provide a cushion base for die cutting.Thus, a substantially all plastic metal foil laminate 21, 22 may beproduced.

In accordance with one aspect of this disclosure, films with relativelylow thermally stability, such as polyolefin films, may be included inthe laminates of this disclosure. In contrast, such low thermally stablefilms, such as polyolefin films, may not be able to survive the hightemperatures associated with chemical etching.

In at least some of the above-described and/or other embodiments,patterned conductive material 50 of the resultant and compound laminates21, 22 may be configured so that the resultant and compound laminatesmay be used in electrical/electronic components such as, but not limitedto, driver panels for electrostatic loudspeakers, or the like. In thisregard, one or more electrical connectors may be connected to thepatterned conductive material 50 in a suitable manner for at leastpartially facilitating operability of the electrical/electroniccomponents.

The above-described exemplary embodiments and associated aspects are inno way intended to limit the scope of the present invention. It will beunderstood by those skilled in the art that while the present disclosurehas been discussed above with reference to exemplary embodiments andaspects thereof, various additions, modifications and changes can bemade thereto without departing from the spirit and scope of theinvention, some aspects of which are set forth in the following claims.

What is claimed is:
 1. A method of laminating, comprising: forming afrangible laminate comprising first, second and third webs, so that thesecond web is positioned between the first and third webs, wherein thesecond web comprises microwave energy interactive material, and theforming of the frangible laminate is comprised of bonding a firstplurality of sections of the second web to the first web, inhibiting atleast some of any bonding between the first plurality of sections of thesecond web and the third web, comprising applying release material, andbonding a second plurality of sections of the second web to the thirdweb; and separating the frangible laminate into parts comprising a firstlaminate and a second laminate, so that the first laminate comprises thefirst web and the first plurality of sections of the second web, and thesecond laminate comprises the third web and the second plurality ofsections of the second web.
 2. The method of claim 1, wherein theseparating of the frangible laminate into the parts is comprised oftearing at least one first section of the first plurality of sections ofthe second web and at least one second section of the second pluralityof sections of the second web apart from one another without there beingany cutting in the second web between the at least one first section andthe at least one second section prior to the tearing of the at least onefirst section and the at least one second section apart from oneanother.
 3. The method of claim 1, wherein the separating of thefrangible laminate into the parts is comprised of tearing the firstplurality of sections of the second web and the second plurality ofsections of the second web apart from one another without there beingany cutting in the second web between the first plurality of sectionsand the second plurality of sections prior to the tearing of the firstplurality of sections and the second plurality of sections apart fromone another.
 4. The method of claim 1, wherein the release materialcomprises silicone.
 5. The method of claim 1, wherein the bonding of thesecond plurality of sections of the second web to the third web iscomprised of applying a continuous flood coating of adhesive materialbetween the release material and the third web.
 6. The method of claim1, wherein: the first laminate is a sacrificial laminate; and theseparating of the frangible laminate into the parts is further comprisedof the sacrificial laminate including at least some of the releasematerial.
 7. The method of claim 1, wherein: the first plurality ofsections of the second web comprises opposite first and second sides;the bonding of the first plurality of sections of the second web to thefirst web is comprised of bonding the first sides of the first pluralityof sections of the second web to the first web; and the applying of therelease material is comprised of applying the release material to thesecond sides of the first plurality of sections of the second web. 8.The method of claim 1, wherein the separating comprises the releasematerial at least partially causing adhesive bond failure between thefirst plurality of sections and the third web.
 9. The method of claim 1,wherein: the first plurality of sections of the second web areconfigured for being scrap microwave energy interactive sections; andthe second plurality of sections of the second web are configured forbeing retained microwave energy interactive sections.
 10. The method ofclaim 1, wherein the second laminate comprises a pattern at leastpartially defined by the second plurality of sections of the second web.11. The method of claim 1, wherein: the bonding of the first pluralityof sections of the second web to the first web is comprised of bondingthe first plurality of sections of the second web to the first web withadhesive material; and the bonding of the second plurality of sectionsof the second web to the second web is comprised of bonding the secondplurality of sections of the second web to the second web with adhesivematerial.
 12. The method of claim 1, wherein the separating comprisesdelaminating the first and second laminates from one another.
 13. Themethod of claim 1, wherein at least one of the first and third webscomprises paper.
 14. The method of claim 1, wherein the microwave energyinteractive material is metallic.
 15. The method of claim 1, wherein themicrowave energy interactive material comprises foil.
 16. The method ofclaim 1, wherein: an initial laminate comprises the first and secondwebs; the forming comprises laminating the initial laminate and thethird web to one another; and the applying of the release material iscomprised of applying the release material to the initial laminate priorto the laminating of the initial laminate and the third web to oneanother.
 17. The method of claim 16, wherein: the first plurality ofsections of the second web comprises opposite first and second sides;the bonding of the first plurality of sections of the second web to thefirst web is comprised of bonding the first sides of the first pluralityof sections of the second web to the first web; and the applying of therelease material is comprised of applying the release material to thesecond sides of the first plurality of sections of the second web. 18.The method of claim 1, further comprising laminating a fourth web to thesecond laminate, so that the second plurality of sections are positionedbetween the third and fourth webs.
 19. The method of claim 18, wherein:the third web comprises paper, and the fourth web comprises a polymerfilm.
 20. The method of claim 18, wherein: the second laminate if aresultant laminate; and a compound laminate comprises the resultantlaminate and the fourth web.
 21. A method of laminating, comprising:forming a frangible laminate comprising first, second and third webs, sothat the second web is positioned between the first and third webs,wherein the second web comprises microwave energy interactive material,and the forming of the frangible laminate is comprised of bonding afirst plurality of sections of the second web to the first web, andbonding a second plurality of sections of the second web to the thirdweb; and separating the frangible laminate into parts comprising a firstlaminate and a second laminate, so that the first laminate comprises thefirst web and the first plurality of sections of the second web, and thesecond laminate comprises the third web and the second plurality ofsections of the second web, wherein the separating of the frangiblelaminate into the parts is comprised of tearing at least one firstsection of the first plurality of sections of the second web and atleast one second section of the second plurality of sections of thesecond web apart from one another without there being any cutting in thesecond web between the at least one first section and the at least onesecond section prior to the tearing of the at least one first sectionand the at least one second section apart from one another.
 22. Themethod of claim 21, wherein the separating of the frangible laminateinto the parts is comprised of tearing the first plurality of sectionsof the second web and the second plurality of sections of the second webapart from one another without there being any cutting in the second webbetween the first plurality of sections and the second plurality ofsections prior to the tearing of the first plurality of sections and thesecond plurality of sections apart from one another.
 23. The method ofclaim 21, wherein the forming of the frangible laminate is furthercomprised of inhibiting at least some of any bonding between the firstplurality of sections of the second web and the third web.
 24. Themethod of claim 23, wherein the inhibiting of at least some of anybonding between the first plurality of sections of the second web andthe third web is comprised of applying release material between thefirst plurality of sections of the second web and the third web.